Electric welding



July 2, 1935. J. v. CAPUTO ELECTRIC WELDiNG Filed March 3, 1953 4 Sheets-Sheet 1 July 2, 1935. J. v. CAPUTO 2,006,912

ELECTRIC WELDING Filed March 3, 1935 4 Sheets-Sheet 2 July 2, 1935. J. v. CAPUTO 2,006,912 ELECTRIC WELDING Filed March 3, 1933 4 Shasta-Sheet 3 INVENTOR Patented July 2, 1935 I 2,006,912

UNITED-STATES PATENT OFFICE ELECTRIC WELDING James V. Caputo, Grafton, Pa. Application March 3, 1933, Serial No. 659,532 29 Claims. (01. 219 4) My invention relates -to electric welding and, in first time in the art, it is also highly useful in particular, to the continuous welding of. metal welding systems utilizing alternating current. lengths, such as pipe, by the resistance method. By using direct current, and providing means Numerous methods and many forms of appawhereby any desired magnitude of current may ratus have been proposed heretofore for welding be supplied to the point of weld, I am able to 5 pipe but, so far as I am aware, substantial obweld heavy wall pipe continuously at speeds jections to all such methods and apparatus have which would not be possible with alternating cur-H been encountered in actual practice. Certain rent welding. methods and apparatus have been successful in In accordance with my invention, I employ a the manufacture of thin gauge tubes having an welding electrode substantially in accordance 10 axial seam connected at intervals by discontinuwith the disclosure of my co-pending applicaous welds. It has been attempted to modify such tion Serial No. 549,441, filed July 8, 1931, for method and apparatus for the manufacture of Welding electrode. I mount this electrode on a heavy wall pipe having a. continuous fluid-tight shaft which is vertically adjustable in a suit- 5 w dable supporting frame. Means for supplying h welding of heavy Wall P p requires electriccurrent to the electrode extend from the rents of such magnitude that the transmission current source, hi h may b l ted at; any thereof 10 the Point Of d becomes a major convenient point. The exact nature of the conproblem. In some types of welders, alternating hectihg means will become apparent as th current is supplied to a rotary electrode from scription of the invention proceeds The ntransformers positioned thereabove or therebemotions are rotatable with t electrode d low. The location of the transformers adjacent suitablevdrive th r f r is provided the electrode considerably obstructs the working For a complete understanding f the ihvenspace and is especially disadvantageous in the non, reference is made to the accompanying "5 case of adlustmg or repan'mg the electrode drawings illustrating a present preferred emstructure- In another type of welder the trans bodiment of the invention and certain modificaforrners rotate with the electrode but are positions thereof In the drawings;

. tioned closely adjacent thereto so that the same Figure 1 is a side elevation, largely diagramobjection of inaccessibility is present. matic of a preferred form of the apparatus;

An objection to all alternating current systems 2 6 1 r ed View of rtion of of electric welding is that the speed of travel of i 15 an g p0 the material must not exceed a given rate for a h line given frequency of the alternating current, if a Figure 3 is sectlonal new along t e III-III of Figure 2; continuous weld 15 to be formed.

" I have overcome these objections to the de- Figure 4 1s p sectlonal VIEW a ong the vices of the prior art by providing means for hne.IV IVIOf t y transmitting electric currents of the desired mag- Flgure 5 1s slmnar new along the hne v v nitude from a convenient point of generation to of figure a, rotating ele tr which is uffi i tl Figure 6 is a partial sectional view taken along tant from the generating source as to be fully 18.11118 VITVI of Flgure 4; accessible at all times and to facilitate the Inanu- Flgure 1S a transverse aml Sectmnal facture of welded pipe. The invention makes it Welding electrod? itself; possible to handle the necessary welding currents Flgure '7A is a De S ti na View Sim a so efficiently as to permit th us of direct cup to Figure 7 illustrating a modified form of elecrent for continuously welding heavy wall pip trode;

which has not been possible heretofore, all appa- Figure 8 a v w imil r o Fi u 6 s win ratus for the manufacture of heavy wall pipe a modification;

with which I am familiar being designed for 1- Figure 9 is a side elevation of a detail; ternating current. While the invention is par- Figure 10 is an end view thereof along the ticularly desirable in conjunction with Welding n of Fi 9 wi h p s in i apparatus, it is also useful in other applications Figures 11 a 12 a e v ews Si ar to Figures where it is desired to deliver a large block of 9 and 10 showing a modification; and

electric energy at low voltage,-either direct cur- Figure 1 s a V Similar to Figures 6 8nd 8 rent or alternating current, to a rotating memshowing a further modification.

her. While the invention permits the use of (11- Referring in detail to the drawings, the invenrect current for welding heavy wall pipe for the tion comprises a welder ll located adjacent the paratus to the welder.

guides l9.

The welder |0 comprises a base l3 having columns 4 at the corners thereof which support a head piece |5. A bearing carriage |6 having guide sleeves l1 surrounding two of the columns I4 is vertically slidable thereon. The bearing carriage is preferably spring supported on hangers |6 from the head casting, as shown in my co-pending application Serial No. 475,174. An adjusting screw I8 is provided for vertically shifting the carriage. Collars |5= on the columns 4 have screws |5 for temporarily supporting the sleeves l1.

Guides |9 are secured to the lower surface of vthe head piece |5 by bolts I9 on the side opposite the bearing carriage l6. A hearing bracket 20 is slidably supported on the guides I9. Actuating screws 2| extend through tapped holes in the bracket for shifting the latter along the A motor 22 and speed reducing gearing'23 are provided for driving the screws 2|. Bolts 24 are provided forclamping the bracket 20 in adjusted position on the head piece |5.

A bearing 25 is carried on a cross bar 26 which is movable vertically within bifurcated lower ends 21 of the bracket 20. The cross bar 26 is normally sustained by spring supports 28. An adjusting screw 29 engages the bearing for effecting vertical adjustment. The vertical adjusting'serews l8 and 29 are'driven through worm and worm wheel reducing gears 30 and 3| by a motor 32 through spur gearing 33 and a shaft 34.

The worm of the drive 3| (not shown) has slidable engagement with the end of the shaft 34 which has a square or other non-circular section. The screws land 29 traverse nuts positioned in the bores of the worm wheels of the drives 30 and 3| in the usual manner.

' Braces 35 extend across the welder on the outside thereof connecting the bearing carriage l6 and the cross bar 26. The braces are integral with the sleeves H at one side of the welder and with similar sleeves H at the other side. The cross bar 26 is secured at each end by bolts 35 to the braces 35 with spacers 36 therebetween.

A shaft 31 is journaled in the bearing 25 and the carriage IS. The structure of the latter may be more fully understood by reference to Figure 5. The bearing 25 is of ordinary construction and requires no detailed explanation. The bearing carriage |6 has anouter raceway 38 which rotatably supports an inner raceway 39 on a plurality of bars or rollers 49. The inner raceway 39 is simply a ring which serves to clamp a plurality of electrically conducting bars 4| into suitably shaped seats formed on the periphery of a disc 42 which is keyed tothe shaft 31 The bars are suitably insulated from the disc and are held in place by clamping brackets 43 and screws 44 in addition to the ring or raceway 39. The end of the shaft 31 projects from the welder and is provided with a coupling yoke 45 fora purpose to be described later.

An electrode 41 is mounted on the' shaft 31. Work-engaging pressure rolls 41 cooperate with the electrode 41. The details of the electrode are illustrated in-Figure 7. A- flanged sleeve 48 is keyed to the shaft 31. Conducting rings 49 and 59- surround the sleeve 48 and are insulated from each other and from the sleeve. Clamping bolts 5| and a disc 52, both of which are insulated from the conducting rings, bind the latter tightly to 2,ooo,9 12

the sleeve 48. The peripheries of the rings 49 and 50 are notched as at 53.

Conducting bars 54 and 55 are welded or brazed alternately to the rings 49 and 50. The bars 54 are welded to the ring 49 between adjacent notches 0n the periphery thereof. The bars 55 extend between the notched portions of the ring 49 and are welded to the portions of the periphery of the ring 56 between notches. Thebars 54 and 55 are preferably of rectangular section, extend laterally of the electrode 41, and are connected to the bars 4| (Figure 5) by any convenient means, such as by slotting and brazing or bolting. Alternatively, the bars 4| may be rectangular in section and integral with the bars 54 and 55.

Conducting rings 56 and 51 embrace the assembled bars 54 and 55, having their inner peripheries notched at 58 for-engaging or clearing the bars, respectively. Bolts 59 secure the rings 56 and 51 together. An electrode disc 69 is secured to the ring 56 by bolts 6| having conical heads seated in countersunk holes in the disc.

The ring 56 has a flange 62 for entering a similarly shaped groove in the disc 60. A similar disc 63 is securedto the ring 51 by the bolts 59 and has a groove 64 for receiving a flange on the ring. Bolts 65 secure the discs and 63 together adjacent their peripheries. The contact between rings on the same side of the central dividing plane of the electrode may be improved by the insertion therebetween of resilient washers of corrugated sheet metal or wire mesh, or of a layer of a conducting paste or amalgam. Shields whichare-preferably grounded, protect the central portion of the electrode from the dirt, grit, heat and moisture usually associated with a weld ing operation.

A shaft 66 is journaled in bearings 61 and 68. The bearing 61 is a simple pedestal bearing while the bearings 68 are similar to the bearing carriage l6 already described, and provide not only a rotatable support for the shaft but also electrical connections extending therealong and fixed relative thereto. A shaft 69 is supported in a bearing 19 similar to the bearing 68 and is coupled to the shaft 66 at 1|. The shaft 69 has a yoke 12 thereon. The yokes 45 and 12 of the shafts 31 and form parts of universal couplings at the ends of a connecting shaft 13. The shaft 66 is driven by a motor 14 through gearing 15.

Referring now particularly to Figures 4 and 6,

spiders 16 are keyed to the shaft 66. Conduct-- ing bars 11 extending in parallel to the axis of the shaft 66 are secured to the spiders 16 by screws 16 but are insulated therefrom. Slip rings 19 embrace the bars 11 on the spiders '16. Each slipassociated therewith are identical with the structure just described except for the length of the bars. 69 is bridged by connections 83 consisting of risers similar to those shown at 82 and strap connections bolted to the risers; A similar construction at the ends of the bars 82 is provided for connecting the bars to conductors 84, the other ends of which The coupling 1| between the shafts 66 and are secured to similar risers extending outwardly from the bars 4|. An insulating disc maintains the conductors 84 properly: separated. Shields 88* enclose the risers connected to the conductors 84 and the projecting ends of the bars ll and 82. A cylindrical shield may also be provided to enclose the cables 86 for receiving an air blast to cool the latter.

Electric current for welding may be supplied to the electrode through the connections just described from any convenient source. I prefer to employ a direct current generator having its leads indicated at 86 extending to a brush holder 81 provided with brushes 88 bearing on the slip rings 19. Instead of a direct current generator, however, I may employ stationary transformers if it is desired to use alternating current. I may also employ rotating transformers, in which case the slip rings 19 and the bars ll may be dispensed with. The transformers are mounted on the shaft 66 as disclosed in my co-pending applications Serial Nos. 453,185 and 475,174, and the transformer secondaries are connected directly to the risers 82. The high voltage current for the transformer primaries is supplied in the usual manner through other slip rings.

An important feature of the invention is that in all portions of the welding circuit, adjacent conductors are of opposite instantaneous polarity if alternating current. is used. This arrangement reduces reactance drop and resistance losses. The arrangement of conductors sb that the magnetic fields thereof are largely neutralized limits the reactance drop and prevents the alternating current resistance'of the circuit from being greatly in excess of the direct current resistance. The total welding current is supplied into a plurality of parallel circuits and the circuit extending to the load is interleaved with that returning therefrom. The structure described also permits large direct currents to be supplied to the welding electrode without excessive loss. The size and strength of the various elements is such that the circuit can be designed to have a very low resistance and a correspondingly high transmission efliciency. A positive drive is provided for the electrode, as well as for the rotating current sup ply connections and synchronous rotation is al-. ways assured. The conducting members are properly supported at all points to withstand the forces resulting from the counteraction of their electromagnetic fields.

The construction of the welder and the electrode permit the removal of the latter from its supporting shaft on one side thereof only. I find that this construction is superior to the former type in which the electrode is supported by fixed bearings on opposite sides thereof. It will be apparent that the right-hand bearing for the electrode shaft is retractible very' readily so that the rings comprising the electrode 41 may be removed over the free end of the shaft. The rings may thus be made continuous with a consequent reduction in the amount of machining necessary.

When it is desired to renew, remove or repair the outer electrode rings 68 and 63, or to have access to the electrode for any other reason, the

right-hand bearing of the shaft 31 may be retracted by the means which has been described in detail. The bolts 24 and 35 and the spacers 36 are first removed. The motor 32 is then operated to withdraw the screws l8 and 28. Hold down screws 28 prevent the cross bar 26 from risingmore than a predetermined distance due to the extension of the springs 28. A yoke 35 is suspended between the braces 35, is adjustable longitudinally thereon, and is provided with a shoe adjustably supported by screws 35 which affords a temporary support for the shaft 31 and the electrode 41 when the bearing 25 is removed. Operation of the motor 22 drives the screws 2| to withdraw the bearing bracket 28 and with it, the bearing 25 and the cross bar 26. The righthand end of the shaft 31 is thus free for removal of the electrode rings or any other'adjustments or repairs which may be necessary.

It will be obvious that the location of the electrical generating and transmitting equipment apart fromthe welder proper where it can be easily supervised and maintained, is a tremendous advantage over the apparatus of the prior art in which the electrical equipment is all exposed to the dirt, grit, heat and moisture which is inevitably present around the welder. The avoidance of obstruction at the welder has already been mentioned. It will be clear that this gives the operator 8. much better opportunity to properly supervise the work than is provided by apparatus which is so closely hedged about with electrical equipment as to make proper superv'ision an impossibility. It will be noted that current is supplied to the electrode from one side only and that the portions of the electrode are removable from the side opposite that to which the power is supplied.

Figure 7A shows a modified form of electrode which is somewhat similar to that shown in Figure '7. 'The modified form comprises a pair of discs 56a and 51a having peripheral rings 68a and 63a therearound. Bridging rings 58a overlap both the discs and the rings and have radiating fins 59a thereon. The various members are bolted together as shown. The rings 58a provide good contact between the discs and the electrode rings and also provide additional heat radiating surface. The electrode rings are provided with a wearing surface 84a of a wearresistant, highly conducting alloy.

Figure 8 illustrates a modified form of slip ring construction in which the shaft 66 is provided with spiders 89. Rods 98 extending through the spiders support rings 9| strung thereon separated by spacers 92. Alternate rings 9| are insulated from the rods 90 and remaining rings have electrical engagement therewith. Lugs 93 depending from the rings 9| are traversed by rods 94 which may contact with alternate rings by means of clamping nuts 95 and are insulated from the remaining rings. 84 have a tapered fit with'risers 96 and bars 91 for similar engagement with the risers.

Figure 10 illustrates a modified form of riser 98 for connecting, the bars 82 to the conductors 84. Bars 89 havea tapered fit with the inner ends of the risers 88 and the outer ends thereof have blocks I88 bolted thereto with recesses ml for receiving cables having their ends brazed therein.

Figures 11 and 12 illustrate a further modification which is similar except that the bars indicated at I82 have slotted terminals I83 welded thereto for cooperation with the slotted inner end of the riser indicated at I88.

Figure 13 illustrates a further modified form of slip ring and connecting bar construction. In Figure 13, the arrangement of spiders, slip rings, spacers, supporting and conducting rods, is

similar to that of Figure 8 with slight differences in detail which will be obvious on inspec- The ends of the rods tion. Corresponding parts are indicated by the same numerals as in Figure 8 with-a prime af-- fixed. The connections extending from the rods 94, however, are bent strap, as shown at I05, instead of jointed bar.

Although I have illustrated and described herein but one preferred embodiment of the invention, together with certain minor modifications thereof, it will be apparent that many changes in the apparatus disclosed may be made without departing from the spirit of the invention or the scope of the appended claims.

I claim:

1. In a welder, base, columns thereon, a head piece on the columns, a bearing carriage slidable on two of the columns, a bearing bracket laterally movable on the head casting, a shaft journaled in said carriage and bracket, an electrode on the shaft, and conductors extending through said carriage to the electrode.

2. Ina welder, base, columns thereon, a head I piece on the columns, a bearing carriage slidable on two of the columns,-a bearing bracket laterally movable on the head easting, a shaft journaled in said carriage and bracket, an electrode on the shaft, braces extending between columns parallel to said shaft, and means connecting a portion of the bracket to the braces.

3. In a welder, a bearing support, a shaft extending therethrough, a disc on the shaft, conductors traversing the disc parallel to the shaft but insulated from the disc and extending on both sides of the support, a ring surrounding the disc, and anti-friction means between said ring and support for rotatably supporting theshaft and conductors.

4. In a welder, a frame, a depending bearing bracket slidable laterally of the frame, a cross bar slidable vertically in said bracket, independent means for actuating said bracket and bar,

and means for securing the bracket and bar,

- from the source into direct engagement with the electrode, a drive for the shaft including a coaxial shaft coupled thereto' and means thereon supporting said conductors in spaced relation.

7. In an apparatus for continuously, electrically welding a seam between metallic edges, a welding electrode adapted to engage said edges, means for causing the 'seam to travel longitudinally while engaged by said electrode, and meansfor delivering to said electrode a current of electricity for heating the edges to be welded, said means including conductors extending axially of, in conducting engagement and rotatable with the elec-' trode, and flexible joints between portions of said conductors.

8. In a welder, a shaft, an electrode mounted thereonybearings on both sides of said electrode for supporting the shaft, and current supply means for said electrode including electrically conducting members engaging the electrode and extending through one of said bearings,

9. In a welder, a frame, abearlng carriage .slidable on said frame, a shaft bearing on said carriage including axial electric conductors insulated from each other and the bearing, and a second shaft bearing adjustable axially and cooperating with the first-mentioned bearing to support an electrode shaft.

10. In a welding apparatus, a shaft, an electrode mounted thereon, conductors extending from the electrode along the shaft, a second shaft substantially aligned with the first and connected thereto, slip rings mounted on said second shaft, means connecting said rings to a low-voltage source of high-amperage welding current, and a drive for at least one of said shafts.

11. Apparatus for driving and supplying heavy currents to a rotary shafbmounted electric consumption device comprising a drive shaft axial with the shaft of the device and coupled thereto, means for actuating the drive shaft, electric conductors extending along the drive shaft in spaced relation, slip rings on said'drive shaft connected to said conductors, and rotating bearings between said rings and said device for supporting said conductors, said bearings including a stationary ring, and a disc rotatable therein, said conductors traversing the disc.

12. Apparatus for electric heating which includes a rotatable electrode, bearings supportingthe electrode, means for progressively advancing the work to be heated in contact therewith, current transmitting conductors extending axially of and connected to the electrode, said conductors being rotatable with said electrode, and bearings rotatably supporting said conductors at points spaced from the electrode. 4

13. In a rotatable electric power connection, a movable, rotatable consuming device adapted to draw current from a set of rings, relatively fixed but rotatable therewith, a shaft connecting the device to said rings, said shaft having universal joints therein, and electrical connections including flexible members extending along said shaft and terminating on said device and said rings.

14. In a rotatable electric power connection, a movable, rotatable consuming device, and a relatively fixed, rotatable current-delivery means,

a shaft connecting the device to said means, and electrical connections'extending along said shafts and into electric-conducting engagement with said device, portions of said shaft and connec: tions having flexible joints therebetween permitting an angular relation of said portions.

15. Apparatus for supplying welding current to.

a shaft-mounted electrode, comprising a plurality of conductors extending axially of the electrode.-

to a current-delivery means adjacent thereto, and a rotatable bearing between the electrode and the means including a stationary sleeve and a disc rotatable therein supporting the conductors.

16. In an apparatus for continuously, electrically welding aseam between metallic edges,

said supply means, the conductors and the electrode I'L Welding apparatus comprising a twin-disc electrode moimted for rotation, conductors extending from said electrode toward one side only thereof, certain of the conductors being connected to each disc of the electrode, said conductors being exposed for external cooling and welding-current supply means spaced a substantial distance from the electrode, cooperating with said conductors and connected thereby directly to the discs.

18. A welder comprising a frame, a carriage adjustable vertically thereon, shaft supports in said carriage, a shaft iournaled in said supports, and a-welding electrode on said shaft, one of said supports being movable axially of the shaft whereby to free an end thereof, and means for moving the support toward the end of the shaft.

19. The apparatus defined by claim 18 characterized by a bracket on said frame for suspending said movable support.

20. The apparatus defined by claim 18 characterized by a bracket depending from said frame and e gaging said movable bearing, and horizontal guides on said frame movably supporting said bracket.

21. In a welder, the combination with a rotating electrode and conductors extending axially thereof toward one side, of a slip ring assembly having a plurality of conductors disposed circumferentially about a common axis, and connections between the last-mentioned conductors and the first-mentioned conductors, said assembly also including rings concentric with said common axis and spaced therealong having engagement with certain of said second-mentioned conductors.

22. The apparatus defined by claim 21 characterlzed by said second-mentioned conductors having electrical connection with alternate rings and being insulated from the other rings.

23. The apparatus defined by claim 21 characterized by said second-mentioned conductors being alternately connected to and insulated frat: each of said rings, passing clrcumferentially 24. The combination with a rotary welding electrode, of a slip ring assembly comprising conductors in spaced relation as elements of a cylinder, connections extending from said conductors to said electrode, slip rings mounted on said conductors, and means supporting said conductors and rings for rotation.

25. The combination with a rotary welding electrode, and a current supply means for said weldingelectrode, of electric conducting mem bers rotatable with the electrode extending between said current supply means and welding electrode and axially of the latter, one end of providing electric-conducting engagement between the current supply means and the electrode, and means for driving at least one of the .shafts.

27. A welder comprising a frame, a carriage adjustable vertically thereon, bearings in said carriage, a shaft journaled in said bearingsand a welding electrode on said shaft, a second shaft having current supply means thereon for the welding electrode and rotatable with said electrode, and connections extending along said shafts between said source and said electrode.

28. The apparatus defined by claim 27 characterized by the electrode being spaced from the current supply means by a distance greater than the length of said first-mentioned shaft to facilitate access to said electrode.

29. In a welder, a frame, a bearing carriage slidable vertically on the frame, a bearing bracket movable laterally inthe frame, a shaft journaled in said carriage and bracket, amelectrode on the shaft. and supply conductors extending through said carriage to the electrode.

JAMES V. CAPUTO. 

